TECHNICAL FIELD
[0001] This invention relates to a catalyst composition for converting an exhaust gas, which
contains an organic nitrogen compound, ammonia, or a combination of them, directly
into N
2 to purify the exhaust gas, a catalyst containing the catalyst composition, and a
method for treating the exhaust gas.
BACKGROUND ART
[0002] An exhaust gas containing an organic nitrogen compound or ammonia (hereinafter referred
to as a nitrogen-based exhaust gas) frequently has a foul odor, and is often harmful
to the human body. Thus, its treatment is demanded.
[0003] Precious metals catalysts such as platinum or palladium, have hitherto been used
for the treatment of the nitrogen-based exhaust gas. These catalysts have high decomposition
activity for organic nitrogen compounds and ammonia, but have high selectivity for
NO
x, such as NO and NO
2. Thus, the resulting NO
x needs to be further reduced into N
2 with the use of denitrification catalysts.
[0004] The following examples have been reported as catalysts with high N
2 selectivity. Firstly, there is a report of a catalyst in which a metal such as Cu
has been sulfated and supported on a silica carrier (see patent document 1).
[0005] With this catalyst, however, the metal has to be kept sulfated during the reaction,
so that a volatile sulfur compound needs to be added to the exhaust gas.
[0006] Next, there is a report of a catalyst having a vanadium oxide, a tungsten oxide,
and palladium carried on titania and/or titania silica, and it is also described that
a copper compound can be used instead of the vanadium oxide and the tungsten oxide
(patent document 2). However, the use of the copper compound is considered to result
in poor activity, and a further improvement is demanded.
[0007] Moreover, a catalyst having a Cu compound supported on carriers such as Al
2O
3 and zeolite is also described (see patent document 3). This catalyst is deemed to
convert acrylonitrile to N
2 at a high selection rate, but there is a demand for a catalyst which has a higher
N
2 selection rate and which can be prepared by a simple method.
[0008] Furthermore, a catalyst for purification of NO
x, which contains copper oxide, ZSM5 and/or zeolite β, and an oxide of at least one
element among magnesium, calcium and silver, is reported for treatment of NO
x in an exhaust gas of a diesel engine (see patent document 4). When this catalyst
is applied to the decomposition of an organic nitrogen compound, the problem arises
that the production of CO and NH
3, which are by-products, increases and the rate of conversion into N
2 decreases.
[0009] EPO800855 discloses a method for cleaning off-gases which contain organic nitrogen compounds,
by catalytic combustion in the presence of excess molecular oxygen at elevated temperature,
using two catalysts, wherein the off-gases are first passed through a catalyst bed
with a metal oxide catalyst and then are passed through a catalyst bed with a noble
metal catalyst and wherein oxidising conditions prevail in both catalyst beds.
[0010] JP7284670 discloses a deodorization catalyst containing activated manganese dioxide, copper
ion carried zeolite and copper oxide, preferably in a weight ratio of 1: (0.5 - 1):
(0.05 - 0.5). This catalyst can be formed into a forming or a coating material.
Patent document 1: Japanese Unexamined Patent Publication No. 1996-173766
Patent document 2: Japanese Unexamined Patent Publication No. 2001-293480
Patent document 3: Japanese Unexamined Patent Publication No. 2004-58019
Patent document 4: Japanese Unexamined Patent Publication No. 2004-167306
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0011] The present invention has been accomplished in the light of the above-described situations.
The invention provides a catalyst composition which decomposes an organic nitrogen-containing
compound or a nitrogen-containing compound such as ammonia at a relatively low temperature
to convert such a compound to N
2 selectively, while suppressing the formation of a by-product such as NO
x, HCN, NH
3, or CO, in the purification of a nitrogen-based exhaust gas, namely, a highly N
2 selective catalyst composition; a catalyst containing the catalyst composition; and
a method for treating the exhaust gas.
MEANS FOR SOLVING THE PROBLEMS
[0012] The inventors diligently conducted studies in an attempt to solving these problems.
As a result, they have found that high N
2 selectivity is obtained by using a catalyst composition formed by mixing copper oxide
particles and zeolite particles. This finding has led to the accomplishment of the
present invention.
[0013] That is, the present invention provides the following:
- (1) A catalyst composition for purifying an exhaust gas containing an organic nitrogen
compound, ammonia, or a combination thereof, wherein
- (a) the catalyst composition contains (i) a copper oxide, (ii) zeolite and (iii) one
or more members selected from the group consisting of Pt, Pd, Ru, Rh, Ir and an alloy
thereof,
- (b) a weight of the copper oxide relative to a sum of a weight of the copper oxide
and a weight of the zeolite is in a range of 0.1 wt.% to 40 wt.%,
- (c) the zeolite in the catalyst composition has a SiO2/Al2O3 molar ratio of 3 to 70, and the zeolite is one or more zeolites of a proton type,
or is one or more zeolites ion-exchanged with a Group 8 metal, a Group 9 metal, a
Group 10 metal or a Group 11 metal,
- (d) the catalyst composition is formed by mixing copper oxide particles and zeolite
particles,
- (e) the catalyst composition is produced by mixing inorganic oxide particles selected
from the group consisting of silica and titania having, carried thereon, the one or
more members selected from the group consisting of Pt, Pd, Ru, Rh, Ir and an alloy
thereof.
- (2) The catalyst composition described in (1), further containing a manganese oxide.
- (3) The catalyst composition described in (2), wherein the weight of the manganese
oxide relative to the sum of the weight of the copper oxide and the weight of the
zeolite is in the range of 0.1 wt.% to 10wt.%.
- (4) The catalyst composition described in any one of (1) to (3), wherein the sum of
the weights of the one or more members selected from the group consisting of Pt, Pd,
Ru, Rh, Ir and an alloy thereof relative to the sum of the weight of the copper oxide
and the weight of the zeolite is in the range of 1 ppm to 500 ppm.
- (5) The catalyst composition described in any one of (1) to (4), wherein the SiO2/Al2O3 molar ratio of the zeolite is 5 to 50.
- (6) The catalyst composition described in any one of (1) to (5), wherein the zeolite
is of a proton type, and is one or more of mordenite, MFI, and β type zeolite.
- (7) A catalyst for purifying an exhaust gas containing an organic nitrogen compound,
ammonia, or a combination thereof, the catalyst comprising:
a catalyst substrate; and
a catalyst layer formed on the catalyst substrate and containing the catalyst composition
described in any one of (1) to (6).
- (8) A method for producing a catalyst for purifying an exhaust gas containing an organic
nitrogen compound, ammonia, or a combination thereof, comprising the steps of:
mixing copper oxide particles, zeolite particles, and silica particles and/or titania
particles to form a mixture, the silica particles and/or the titania particles having,
carried thereon, one or more members selected from the group consisting of Pt, Pd,
Ru, Rh, Ir and an alloy thereof;
forming the mixture into a slurry; and
coating the slurry onto a catalyst substrate to form a catalyst layer.
- (9) A method for treating an exhaust gas, comprising the step of:
bringing an exhaust gas containing an organic nitrogen compound, ammonia, or a combination
thereof into contact with a catalyst at 250 to 600°C to convert the exhaust gas into
N2, the catalyst containing a catalyst composition formed by mixing a copper oxide powder,
a zeolite powder, and silica particles and/or titania particles, the silica particles
and/or titania particles having, carried thereon, one or more members selected from
the group consisting of Pt, Pd, Ru, Rh, Ir and an alloy thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
[Fig. 1] Fig. 1 shows the N2 yields of Catalysts I, II, VII and VIII and Catalysts A and F as Comparative Examples
at reaction temperatures of 300 to 450°C.
[Fig. 2] Fig. 2 shows the N2 yields of Catalyst IX and Catalyst E as Comparative Example at 300 to 450°C.
[Fig. 3] Fig. 3 shows the N2 yields of Catalysts II, XI and XII from ammonia at 300 to 400°C.
BEST MODE FOR CARRYING OUT THE INVENTION
[0015] The catalyst composition of the present invention contains a copper oxide and zeolite
and is formed by mixing copper oxide particles and zeolite particles. By using copper
oxide particles rendered ready for use, it becomes possible to easily control the
powder characteristics of the copper oxide particles, such as mean particle diameter
and particle size distribution, thereby improving catalytic performance. In addition,
a catalyst showing comparable or better performance can be produced by a simple method,
as compared with a method in common use, such as the impregnation process or the coprecipitation
process.
[0016] Herein, the copper oxide refers to an oxide containing copper, and includes a copper-containing
compound oxide. For example, copper oxide represented by the compositional formula
CuO
x (0.45≤x≤1.1) is named, and typical examples are CuO and CU
2O. Copper oxides of a plurality of compositions may be combined and used. A commercially
available copper oxide can be used, and a mixture of oxides including a copper oxide
may be used. For example, CuO in hopcalite may be used.
[0017] No limitations are imposed on the shape of the copper oxide particles used in the
present invention, and a spherical shape, a semispherical shape, a cubic shape, and
a scaly shape are included in the shape of these particles. The mean particle diameter
of the copper oxide is 0.01 µm or more, preferably 0.05 µm or more, but 5 µm or less,
from the point of view of catalytic performance. Unless otherwise specified, the mean
particle diameter herein refers to the particle diameter of secondary particles. It
is assumed that the mean particle diameter of the copper oxide particles is changed
to control the state of contact of the copper oxide particles with the zeolite particles,
thereby achieving a high N
2 selection rate, while suppressing the formation of undesirable components, such as
NO
x, N
2O, HCN, NH
3, and CO, although any theory is non-binding.
[0018] The zeolite may be a naturally occurring product or a synthetic product. Examples
of the naturally occurring zeolite are mordenite, erionite, ferrierite, and Chabazite.
Examples of the synthetic product are x-type zeolite; Y-type zeolite; MFI-type zeolite
such as ZSM-5; L-type zeolite; A-type zeolite; and β-type zeolite. Typical examples
of the zeolite are HY-type zeolite available as LZY-84 of UOP, silicalite available
as MFI-40 of UOP, β-type zeolite available as BETA-ZEOLITE zeolite of UOP, and mordenite
available as LSM-8 of UOP. The use of mordenite, MFI-type and β-type zeolites among
these zeolites and in which the molar ratio between silica and alumina (SiO
2/Al
2O
3 molar ratio), the constituents of the zeolite, is 3 or higher, preferably 5 or higher,
but 70 or lower, more preferably 5 to 50, particularly preferably 5 to 30 obtains
a catalyst which results in the high decomposition rate of an organic nitrogen compound,
involves little formation of NO
x, N
2O, NH
3 and CO, and gives a high N
2 conversion rate.
[0019] The zeolite used in the present invention may be of a proton type, or of a substituted
type to be described below. A mixture of the proton-type zeolite and the substituted
zeolite may be used as the zeolite. The proton-type zeolite refers to zeolite in which
at least some of the ion-exchangeable cation sites are accounted for by H
+. For example, mordenite of the proton type is indicated as H-mordenite, the proton
type of ZSM-5 as an example of the MFI-type zeolite is indicated as H-ZSM5, and the
proton type of β-type zeolite is indicated as H-β zeolite. The proton-type zeolite,
in which the molar ratio of the content of Na ions or K ions introduced upon ion exchange
(these alkali metal elements are expressed as M) relative to the SiO
2 content (the molar ratio as an oxide, i.e., M
2O/SiO
2) is 0 to 0.1, preferably 0 to 0.05, more preferably 0 to 0.03, is used particularly
preferably as a catalyst component of the present invention for the purpose of an
increase in the N
2 selection rate.
[0020] The substituted zeolite refers to zeolite in which at least some of the ion-exchangeable
cation sites are accounted for by cations other than protons (i.e., substituting cations),
namely metallic cations. Hereinafter, the substituted zeolite, in which the substituting
cations are metallic cations, is expressed as metal-substituted zeolite. Herein, the
proton-type Y-type zeolite is expressed as HY-type zeolite, the Y-type zeolite in
which Fe cations account for the cation sites is expressed as Fe-Y-type zeolite, and
the Y-type zeolite in which NH
4+ accounts for the cation sites is expressed as NH
4-Y-type zeolite. Other zeolites are also expressed similarly. Moreover, zeolites substituted
by Fe cations are expressed collectively as Fe-zeolite. Likewise, zeolites substituted
by Cu cations and Co cations are expressed collectively as Cu-zeolite and Co-zeolite,
respectively.
[0021] The substituting metal accounting for the ion-exchangeable cation sites of the metal-substituted
zeolite is selected from Group 8 metals such as Fe; Group 9 metals such as Co and
Rh; Group 10 metals such as Ni and Pd; and Group 11 elements such as Cu and Ag. The
preferred substituting metals are Fe, Cu, Ni, Co and combinations of them.
[0022] In the present invention, the catalyst, which uses zeolite substituted by an alkali
metal such as Na or K, or zeolite substituted by an alkaline earth metal such as Mg
or Ca, among the metal-substituted zeolites, has a low N
2 conversion rate for the organic nitrogen compound, in comparison with zeolite substituted
by a metal such as Fe, Cu, Co or Ni. Thus, the alkali metal- or the alkaline earth
metal-substituted zeolite is preferably limited, as a metal oxide, to 1.0% by weight
or less, preferably 0 to 0.5% by weight, more preferably 0 to 0.3% by weight, based
on the catalyst composition.
[0023] Hence, zeolite substituted by Fe, Cu, Ni or Co is illustrated as the metal-substituted
zeolite used preferably in the present invention. Such zeolites may be used singly
or in combination. The amount of the substituting metal ions of Fe, Cu, Ni or Co is
selected, as appropriate, depending on the SiO
2/Al
2O
3 molar ratio of the zeolite. Generally, the total amount of the substituting ions
is in the range of 1 to 6 wt.% relative to the weight of the zeolite.
[0024] When the mean particle diameter of the copper oxide particles is in the range of
0.01 to 1 µm, the mean particle diameter of the zeolite particles used in the present
invention is typically 1 µm or more, preferably 2 µm or more, but 50 µm or less, preferably
30 µm or less. The (mean particle diameter of the zeolite particles)/(mean particle
diameter of the copper oxide particles) ratio is not limited. However, this ratio
is typically 10 or higher, preferably 20 or higher, but 200 or lower, preferably 100
or lower. This mean particle diameter ratio is selected so as to promote contact between
the zeolite particles and the copper oxide particles in the catalyst layer.
[0025] In the catalyst composition of the present invention, the weight of the copper oxide
relative to the sum of the weights of the copper oxide and the zeolite is 0.1 wt.%
% or higher, preferably 0.5 wt.% % or higher, more preferably 1.0 wt.% or higher,
further preferably 2.0 wt.% or higher, but 40 wt.% or lower, preferably 30 wt.% or
lower. If the proportion is less than the above-mentioned range, the activity of decomposing
the organic nitrogen compound or ammonia, which is the purpose of the present invention,
may be insufficient, or the conversion to N
2 as the object of the present invention may be insufficient. If the above range is
exceeded, the formation of NO
x is promoted, with the result that conversion to N
2 may be insufficient.
[0026] The catalyst composition of the present invention contains one or more precious metals
selected from the group consisting of Pt, Pd, Ru, Rh, Ir, an alloy of them, or a mixture
of them.
[0027] Particles of the precious metal are supported on heat-resistant inorganic oxide particles
selected from the group consisting of silica and titania, and may exist in a state
mixed with zeolite particles.
[0028] Preferably, these heat-resistant inorganic oxide particles are spherical or semispherical,
have a mean particle diameter of 1 to 30 µm, and have the above-mentioned precious
metal carried thereon with a metal content in the range of 0.01 to 2.0% by weight.
[0029] The proportion of the weight of the precious metal in the catalyst composition of
the present invention is 1 ppm or more, preferably 2 ppm or more, further preferably
5 ppm or more, but 1,000 ppm or less, preferably 500 ppm or less, further preferably
200 ppm or less, relative to the sum of the weights of the copper oxide and the zeolite.
[0030] The catalyst composition of the present invention containing the precious metal component
in the above range is useful for converting an organic nitrogen compound and/or ammonia,
contained in an exhaust gas, into N
2 at a high selection rate when placed at a temperature in the range of 250 to 600°C,
preferably 300 to 500°C, more preferably 300 to 450°C, further preferably 300 to 400°C;
for preventing unburned carbonaceous components or high-boiling components, such as
tar, from remaining on the catalyst; and for suppressing the formation, as by-products,
of intermediate products (e.g., CO) derived from hydrocarbon components. Furthermore,
the catalyst composition containing the precious metal component exhibits the effects,
particularly, in suppressing the tendency toward increases in by-products, such as
CO and NH
3, due to catalyst deterioration occurring during long-term use, and curtailing a decrease
in the rate of conversion of the organic nitrogen compound and ammonia into N
2, namely, suppressing decline in activity, during treatment of an exhaust gas containing
an acidic component such as SO
2 in an amount of the order of 1 to 200 ppm.
[0031] The addition of the precious metal to the catalyst composition can be performed using
various publicly known means.
In one mode, after the precious metal is carried on a material other than the copper
oxide and zeolite, the resulting composite may be mixed with the copper oxide and
zeolite. The material as the carrier of the precious metal may have or lack catalytic
activity toward organic nitrogen compounds or ammonia, and is preferably heat resistant.
The material is selected from the group consisting of silica and titania. In particular,
a catalyst composition in which silica or titania particles supporting Pt or Ru are
mixed with copper oxide and zeolite particles is excellent, particularly, in the effect
of decomposing organic nitrogen compounds nearly completely, and converting them into
N
2 at a high rate.
[0032] The catalyst composition of the present invention, in another mode, may contain a
manganese oxide. By adding the manganese oxide, it may be possible to suppress the
formation of CO. If the catalyst composition of the present invention contains manganese
oxide, the weight of manganese oxide relative to the sum of the weights of the copper
oxide and zeolite is preferably 0.1 wt.% or more, but 10 wt.% or less. If this weight
percentage is less than the above range, the effect of the manganese oxide may be
difficult to detect. If the above range is exceeded, the formation of NO
x and N
2O may be promoted. The manganese oxide refers to an oxide containing manganese, and
also includes a manganese-containing compound oxide. The manganese oxide includes,
for example, manganese oxide represented by the compositional formula MnO
x (0.99≤x≤2.1), and its examples are MnO, Mn
2O
3, and MnO
2. A plurality of manganese oxides may be combined and used. No limitation is imposed
on the average valence of the manganese oxide, but typically, the average valence
is 2.5 or higher, preferably 2.9 or higher, but 4.1 or lower. The manganese oxide
may be supplied in the form of a mixture with an oxide of other metal. For example,
MnO
2 in hopcalite can be used as the manganese oxide.
[0033] The incorporation of an alkali metal oxide or an alkaline earth metal oxide, such
as Na
2O, K
2O, CaO or MgO, decreases the decomposition rate of the organic nitrogen compound,
and further becomes the cause of an increase in CO due to activity decline during
long-term use. Thus, the incorporation of such a metal oxide, as an oxide, is preferably
limited to 1.0% by weight or less, more preferably 0 to 0.5% by weight, further preferably
0 to 0.3% by weight.
[0034] The illustrative formulation of the catalyst composition of the present invention
will be described below.
[0035] Discussed herein is a catalyst composition containing a copper oxide and proton-type
zeolite, and the weight of the copper oxide relative to the sum of the weights of
the copper oxide and the proton-type zeolite is in the range of 2.0 to 20 wt.%.
[0036] Also discussed herein is a catalyst composition containing a copper oxide, proton-type
zeolite and a precious metal, the weight of the copper oxide relative to the sum of
the weights of the copper oxide and the proton-type zeolite is in the range of 0.5
to 10 wt.%, and the sum of the weight of the precious metal is in the range of 2 to
500 ppm.
[0037] Also discussed herein is a catalyst composition containing a copper oxide, proton-type
zeolite having an SiO
2/Al
2O
3 molar ratio of 5 to 50, and a precious metal, the weight of the copper oxide relative
to the sum of the weights of the copper oxide and the proton-type zeolite is in the
range of 2 to 30 wt.%, and the sum of the weight of the precious metal is in the range
of 2 to 500 ppm.
[0038] Also discussed herein is a catalyst composition containing a copper oxide, proton-type
zeolite having an SiO
2/Al
2O
3 molar ratio of 5 to 50 and being one or more of mordenite, MFI zeolite, and β-type
zeolite, and a precious metal, the weight of the copper oxide relative to the sum
of the weights of the copper oxide and the proton-type zeolite is in the range of
2 to 30 wt.%, and the sum of the weight of the precious metal is in the range of 2
to 500 ppm.
[0039] In one aspect, the catalyst composition of the present invention contains a copper
oxide, proton-type zeolite, and a precious metal, the weight of the copper oxide relative
to the sum of the weights of the copper oxide and the proton-type zeolite is in the
range of 1.0 to 10 wt.%, and the sum of the weight of the precious metal is in the
range of 2 to 500 ppm. The precious metal is carried on silica particles, titania
particles, or a mixture thereof, and these particles are mixed with copper oxide particles
and proton-type zeolite particles.
[0040] In another aspect, the catalyst composition of the present invention contains a copper
oxide, proton-type zeolite having an SiO
2/Al
2O
3 molar ratio of 5 to 50 and being one or more of mordenite, MFI zeolite, and β-type
zeolite, and a precious metal, the weight of the copper oxide relative to the sum
of the weights of the copper oxide and the proton-type zeolite is in the range of
1.0 to 30 wt.%, and the sum of the weight of the precious metal is in the range of
2 to 500 ppm. The precious metal is Pt or Ru, and is carried on silica particles,
titania particles, or a mixture thereof, and these particles are mixed with copper
oxide particles and proton-type zeolite particles.
[0041] Also discussed herein is a catalyst composition containing a copper oxide, and meta-substituted
zeolite substituted by one or more of Fe, Cu, Ni and Co, and the weight of the copper
oxide relative to the sum of the weights of the copper oxide and the metal-substituted
zeolite is in the range of 1.0 to 15 wt.%
[0042] In another aspect, the catalyst composition of the present invention contains a copper
oxide, meta-substituted zeolite substituted by one or more of Fe, Cu, Ni and Co, and
a precious metal, the weight of the copper oxide relative to the sum of the weights
of the copper oxide and the metal-substituted zeolite is in the range of 1.0 to 10
wt.%, and the sum of the weight of the precious metal is in the range of 2 to 500
ppm. The precious metal is carried on silica particles, titania particles, or a mixture
thereof, and these particles are mixed with copper oxide particles and proton-type
zeolite particles.
[0043] In another aspect, the catalyst composition of the present invention contains a copper
oxide, meta-substituted zeolite substituted by one or more of Fe, Cu, Ni and Co, and
a precious metal, the weight of the copper oxide relative to the sum of the weights
of the copper oxide and the metal-substituted zeolite is in the range of 1.0 to 30
wt.%, the SiO
2/Al
2O
3 molar ratio of the metal-substituted zeolite is 5 to 50, and the sum of the weight
of the precious metal is in the range of 2 to 500 ppm. The precious metal is carried
on silica particles, titania particles, or a mixture thereof, and these particles
are mixed with copper oxide particles and metal-substituted zeolite particles.
[0044] Also discussed herein is a catalyst composition containing a copper oxide, metal-substituted
zeolite substituted by one or more of Fe, Cu, Ni and Co, and MnO
2 and, relative to the sum of the weights of the copper oxide and the metal-substituted
zeolite, the weight of the copper oxide is in the range of 1.0 to 10 wt.% and the
weight of the manganese oxide is in the range of 0.5 to 10 wt.%.
[0045] Also discussed herein is a catalyst composition containing a copper oxide, meta-substituted
zeolite substituted by one or more of Fe, Cu, Ni and Co, and MnO
2 and, relative to the sum of the weights of the copper oxide and the metal-substituted
zeolite, the weight of the copper oxide is in the range of 1.0 to 10 wt.% and the
weight of the manganese oxide is in the range of 0.5 to 10 wt.%. The copper oxide
and the manganese oxide are components of hopcalite.
[0046] The catalyst composition of the present invention is produced by mixing copper oxide
particles and zeolite particles. There is no limitation on means of mixing, and an
arbitrary publicly known means, such as dry mixing or wet mixing, can be used. The
use of dry mixing enables a powdery catalyst composition to be produced, while the
use of wet mixing enables a slurry catalyst composition to be produced. During mixing,
components other than the copper oxide and the zeolite may be mixed in combination,
and after the copper oxide particles and the zeolite particles are mixed, the other
components may be mixed. As the other components, a binder component, precious metal-carried
silica particles, and precious metal-carried titania particles are named. The mean
particle diameter of these precious metal-carried particles is generally in the range
of 0.5 to 20 µm. Various publicly known binders can be used as the binder, and their
examples are colloidal silica, alumina sol, silicate sol, and boehmite. As noted here,
the catalyst composition of the present invention may be in the form of a powder,
pellets, or a slurry.
[0047] The present invention also relates to a catalyst having a catalyst layer formed on
a catalyst substrate (may be called a structural body), the catalyst layer containing
the above-described catalyst composition. A typical catalyst is of a form having the
catalyst layer formed on the surface of the catalyst substrate with the use of the
catalyst composition containing the copper oxide and the zeolite. In the catalyst
layer, therefore, copper oxide particles and zeolite particles exist in a mixed state,
the particles are fixed to each other by a suitable binder, and the particles and
the substrate are fixed together by a suitable binder. The thickness of the catalyst
layer is generally in the range of 10 to 1000 µm. No limitation is imposed on the
shape of the catalyst substrate used, and the preferred shape is such that a differential
pressure generated during gas passage is small, and that the area of contact with
the gas is large. The preferred shapes include a honeycomb, corrugations, a foamed
metal, a sheet, a mesh, a fiber, a pipe, and a filter. There is no limitation on the
material for the substrate, and examples of the material are hopcalite, cordierite,
alumina, silica alumina, a carbon fiber, a metal fiber, a glass fiber, a ceramic fiber,
and a metal such as stainless steel. The material for the substrate preferably has
excellent corrosion resistance and excellent heat resistance.
[0048] An illustrative method of producing the catalyst of the present invention will be
described. First, a mixture of copper oxide particles and zeolite particles is formed.
If the aforementioned catalyst composition is powdery, this catalyst composition may
be used as the mixture. Water and, in some cases, a binder are added to the mixture,
and these materials are kneaded to form a slurry. If the aforementioned catalyst composition
is in a slurry form, the catalyst composition may be used as the slurry for a subsequent
step. The step of mixing the copper oxide particles and the zeolite particles, and
the step of forming the mixture into the slurry may be performed sequentially, continuously
or simultaneously. Where necessary, the manganese oxide and/or the precious metal
may be added in the mixing step and/or the slurrying step. The resulting slurry is
coated onto the catalyst substrate, and dried. No limitation is imposed on the coating
method, and a publicly known method including wash coating or dipping can be used.
If desired, these operations are repeated, whereby the thickness of the catalyst layer
can be adjusted.
[0049] Also discussed herein is an exhaust gas purification apparatus using the above-described
catalyst. The exhaust gas purification apparatus has an exhaust gas channel, and the
interior of the channel is provided with a first catalyst region accommodating the
catalyst of the present invention, and a second catalyst region accommodating a precious
metal-carried catalyst. The second catalyst region (succeeding stage) is located downstream
of the first catalyst region (preceding stage). In the channel, another catalyst region
may be further installed. Various publicly known catalysts, for example, a platinum
catalyst carried on alumina (expressed as Pt/Al
2O
3) can be used as the precious metal-carried catalyst accommodated in the second catalyst
region. The precious metal-carried catalyst preferably has the ability to oxidize
hydrocarbon. By installing the precious metal-carried catalyst in the succeeding stage,
the unreacted hydrocarbon and/or Co flowing in from the preceding stage can be oxidized
to prevent discharge of harmful components.
[0050] A region accommodating an adsorbent or a decomposing catalyst for capturing or decomposing
a catalytic poison component in the exhaust gas may be further provided in the channel
upstream of the region where the catalyst of the present invention is accommodated.
In treating the exhaust gas containing organosilicon together with the organic nitrogen
compound, for example, a catalyst containing a mixture of precious metal-carried alumina
particles and zeolite particles (1:99 to 70:30; weight ratio) is provided upstream
of the catalyst of the present invention, whereby the life of the catalyst of the
present invention can be improved markedly.
[0051] Examples of the organic nitrogen compound which can be treated with the catalyst
of the present invention are nitriles such as acetonitrile and acrylonitrile; amides
such as formamide and dimethylformamide; amines such as methylamine, ethylamine, dimethylamine,
diethylamine, trimethylamine, and triethylamine; proteins; amino acids; alkanolamines
such as ethanolamine; heterocyclic compounds such as pyrrole, imidazole, pyrazole,
pyridine, pyrazine, pyrimidine, pyridazine, and pyrrolidone; ammonium compounds such
as quaternary ammonium compounds; and imide compounds or urethane compounds having
uses as paint components or fiber components. The organic nitrogen compound refers
to a compound containing at least one nitrogen atom in a molecule.
[0052] The exhaust gas containing the organic nitrogen compound and/or ammonia is generated
in a manufacturing process for these compounds, various processes using these compounds
as raw materials or solvents, and various processes where these compounds are by-products.
For example, the exhaust gas occurs in the roasting of coffee; waste water treatment;
treatment and processing of plants or animals; food processing; production of synthetic
fibers, synthetic rubbers or synthetic resins having nitrile as a polymeric unit;
a coating process using a paint containing the organic nitrogen compound as a solvent
or a paint component; and a painting process (e.g., an electrodeposition process)
or a baking process for polyimide or an acrylic paint. In any of the exhaust gases,
an organic solvent, other organic compound, or a heat decomposition product exists
normally in addition to the organic nitrogen compound. In the exhaust gas generated
from roasted coffee, for example, organic compounds, such as cellulose, hemicellulose,
fatty acids, and caffeine, are incorporated in addition to organic nitrogen compounds
such as proteins, amino acid, or their heat-denaturation components. The catalyst
of the present invention can be used in the treatment of the exhaust gas containing
these organic nitrogen compounds and/or ammonia and other organic compound components.
[0053] The catalyst of the present invention shows a high decomposition rate and high N
2 selectivity for the organic nitrogen compound and/or ammonia not only at a low space
velocity (e.g., SV of 3,000 hr
-1; SV denotes the ratio of the volume of the gas passed to the volume of the catalyst
per unit time), but also at a high space velocity (e.g., SV = 50,000 to 100,000 hr
-1), and can decrease the formation of undesirable by-products such as NO, NO
2, NH
3, HCN, and nitrogen-containing intermediates (e.g., amine, imine, and imide) and CO.
In the case of the honeycomb-shaped catalyst, SV refers to the ratio of the volume
of the exhaust gas passed per hour to the volume of the honeycomb body including its
space portions. In the case of the catalyst layer packed with a particulate catalyst
such as an extrudate, SV refers to the ratio of the volume of the exhaust gas passed
per hour to the volume of the packed layer.
[0054] In the exhaust gas treated with the catalyst of the present invention, oxygen in
an amount at least necessary for an oxidation reaction is preferably contained, since
organic components in the exhaust gas are to be oxidized and removed as CO
2.
[0055] When the catalyst of the present invention is brought into contact with the exhaust
gas, which contains 1 to 1,000 ppm by weight of the organic nitrogen compound and/or
ammonia as a nitrogen content, at a temperature of 250°C or higher, preferably 300°C
or higher, more preferably 300°C or higher, but 600°C or lower, preferably 500°C or
lower, more preferably 450°C or lower, further preferably 300 to 400°C, these components
are efficiently decomposed, and a high N
2 selection rate is obtained.
Examples
[0056] The present invention will be described in more detail based on the Examples, which
in no way limit the invention.
Preparation of NH4-mordenite (NH4-SCM5)
[0057] Na-type mordenite (SCM-5 produced by UOP, SiO
2/Al
2O
3 molar ratio 10.7, mean particle diameter 5.6 µm) (600 g), 300 g of ammonium chloride,
and 2,300 g of deionized water were mixed, and stirred for 3 hours at 80°C. Then,
the mixture was filtered by suction, and washed twice with 2 liters of water each.
Then, the filter cake recovered was dried for 5 hours at 150° by a dryer to obtain
NH4-mordenite (NH
4-SCM5).
[Preparation of metal-substituted zeolite]
Preparation of Fe-mordenite
[0058] Ferric chloride tetrahydrate (42.7 g) was dissolved in 1,557 g of deionized water,
and 404 g of
NH4-mordenite (the above-mentioned NH
4-SCM5) was further added. To the resulting mixture, a 28% aqueous solution of ammonia
was added, with stirring and with pH being measured, until a pH of 8.0 was reached.
After stirring was continued, the mixture was filtered by suction. A solid filtered
off was washed with deionized water, and then dried for 5 hours at 150°C. The solid
was further calcined for 2 hours at 500°C in an air stream in a muffle furnace to
obtain Fe-mordenite.
Preparation of Cu-mordenite
[0059] Copper nitrate trihydrate (1.4 g) was dissolved in 389 g of deionized water, and
a 28% aqueous solution of ammonia was added to adjust the pH to 10.5-11. To the resulting
mixture, 101 g of
NH4-mordenite (the above-mentioned NH
4-SCM5) was added. After stirring, the mixture was filtered by suction. A solid filtered
off was washed with deionized water, and then dried for 5 hours at 150°C. The solid
was further calcined for 2 hours at 500°C in an air stream in a muffle furnace to
obtain Cu-mordenite.
Preparation of Cu-ZSM5
[0060] Copper acetate (4.0 g) was dissolved in 500 cc of water, and the solution was held
at 80°C. To the solution, 29 g of NH
4-MFI-40 (zeolite produced by UOP, SiO
2/Al
2O
3 molar ratio 40) was added, and the mixture was stirred for 3 hours. After filtration
and washing were performed, the filter cake recovered was dried for 3 hours at 150°C.
A powder filtered was ion-exchanged again by the same method using the same solution
as described above. After two ion-exchanges, the powder was calcined for 4 hours at
500°C to prepare Cu-ZSMS.
[Production of catalyst]
<Examples>
Catalyst 1 - for exemplary purposes only and does not form a part of the invention
[0061] The aforementioned NH
4-SCMS powder (25 g) and 0.56 g of a CuO powder (produced by Chemilite Corp., mean
particle diameter 0.52 µm) were mixed in a mortar to become uniform. To the resulting
mixture, 28 g of alumina sol as a binder and 26 g of deionized water were added, and
these materials were thoroughly kneaded to obtain a slurry. The slurry was wash-coated
onto a ceramic corrugated honeycomb substrate (produced by NICHIAS CORP., diameter
21 Φx length 50 mm, cell count: 200 cells/square inch). The coated substrate was dried
for 2 hours at 150°C by a dryer, and further calcined for 1 hour at 500°C in an air
stream in a muffle furnace to obtain Catalyst I.
[0062] The proportion of CuO in Catalyst I, represented by the following equation

(unless otherwise indicated, the proportion of each component will hereinafter be
expressed as the proportion to the sum of
(weight of CuO + weight of zeolite), was 2.2 wt.%.
Catalysts II and III - for exemplary purposes only and does not form a part of the
invention
[0063] Catalysts II and III were produced in the same manner as for Catalyst I, except that
the amounts of the NH
4-SCM5 powder and the CuO powder mentioned above were selected such that the proportion
of CuO would become 6.9 wt.% (Catalyst II) and 12.3 wt.% (Catalyst III).
Catalyst IV - for exemplary purposes only and does not form a part of the invention
[0064] Catalyst IV was produced in the same manner as for Catalyst I, except that 25.2 g
of an Fe-mordenite powder (mean particle diameter 4.2 µm) was used instead of the
NH
4-SCM5 and the amount of the CuO powder was set at 0.52 g. The proportion of CuO in
Catalyst IV was 2.2 wt.%.
Catalyst V - for exemplary purposes only and does not form a part of the invention
[0065] Catalyst V was produced in the same manner as for Catalyst IV, except that 0.19 g
of a hopcalite powder was used instead of the CuO powder and the amount of the Fe-mordenite
was set at 25.5 g. The proportion of CuO in Catalyst V was 0.2 wt.%. The hopcalite
used was a product of SÜD-CHEMIE, its composition was as shown below, and its mean
particle diameter was 7.3 µm.
MnO2: 72.6 wt.%; Cuo: 21.1 wt.%; K2O: 3.7 wt.% Catalyst VI - for exemplary purposes only and does not form a part of
the invention
[0066] Catalyst VI was produced in the same manner as for Catalyst V, except that the amount
of the hopcalite powder was set at 0.56 g and 25.2 g of Cu-mordenite was used instead
of 25.5 g of the Fe-mordenite. The proportion of CuO in Catalyst VI was 0.5 wt.%.
Catalyst VII - for exemplary purposes only and does not form a part of the invention
[0067] Catalyst VII was produced in the same manner as for Catalyst V, except that the amounts
of the Cu-zeolite and the hopcalite were selected such that the proportion of CuO
would become 0.8 wt.%.
Catalyst VIII
[0068] A slurry was prepared using 487 g of the aforementioned NH
4-SCM5, 10.5 g of a CuO powder, 17.5 g of a Pt-carried SiO
2 powder (the amount of Pt carried: 0.04 wt.%), 525 g of alumina sol, and 460 g of
deionized water. Using this slurry, Catalyst VIII was produced in the same manner
as for Catalyst I.
Catalyst IX - for exemplary purposes only and does not form a part of the invention
[0069] Catalyst IX was produced in the same manner as for Catalyst I, except that H-ZSM5
(H-MFI40 produced by UOP, SiO
2/Al
2O
3 molar ratio 40 (a product comparable to H-ZSM5), mean particle diameter 2.8 µm) was
used instead of the NH
4-SCM5, silica sol was used instead of the alumina sol, and the weights of the H-ZSM5
and CuO were selected such that the proportion of CuO in the catalyst would become
6.0 wt.%.
Catalyst X - for exemplary purposes only and does not form a part of the invention
[0070] Catalyst X was produced in the same manner as for Catalyst V, with the amounts of
a CuO powder, a manganese oxide powder (produced by Carus Chemical company) and the
aforementioned NH
4-SCM5 being selected such that the proportion of CuO would become 6.3 wt.% and the
proportion of manganese oxide would become 0.7 wt.%.
Catalyst XI - for exemplary purposes only and does not form a part of the invention
[0071] Catalyst XI was produced in the same manner as for Catalyst V, except that the amounts
of the aforementioned Fe-zeolite and the aforementioned hopcalite were selected such
that the proportion of CuO would become 1.7 wt.%, and that 32 g of silica sol was
used instead of the alumina sol as a binder.
Catalyst XII
[0072] A slurry was prepared using 105 g of the aforementioned NH
4-SCM5, 14.0 g of a CuO powder, 35 g of a Pt-carried TiO
2 powder (the amount of Pt carried: 0.04 wt.%), 105 g of alumina sol, and 240 g of
deionized water. Using this slurry, Catalyst XII was produced in the same manner as
for Catalyst I.
Catalyst XIII - for exemplary purposes only and does not form a part of the invention
[0073] Catalyst XIII was produced in the same manner as for Catalyst I, except that the
amounts of a CuO powder and proton-type zeolite were selected such that the proportion
of CuO would be 24 wt.%, and the proportion of H-type mordenite having a SiO
2/Al
2O
3 molar ratio of 18 (LZM8 produced by UOP) would be 76 wt.%.
Catalyst XIV - for exemplary purposes only and does not form a part of the invention
[0074] Catalyst XIV was produced in the same manner as for Catalyst I, except that the amounts
of a CuO powder and proton-type zeolite were selected such that the proportion of
CuO would be 13 wt.%, and the proportion of the same H-type mordenite (LZM8 produced
by UOP) as that used for Catalyst XIII would be 87 wt.%.
Catalyst XV
[0075] Catalyst XV was produced in the same manner as for Catalyst XIV, except that a CuO
powder and the aforementioned
H-type mordenite (LZM8 produced by UOP) were used in the same proportions as for Catalyst
XIV, and a Pt-carried TiO
2 powder (the amount of Pt carried: 0.04 wt.%) was further added.
Catalyst XVI
[0076] Catalyst XVI was produced in the same manner as for Catalyst XV, except that a Pt-carried
SiO
2 powder (the amount of Pt carried: 0.04 wt.%) was used instead of the Pt-carried TiO
2 powder.
Catalyst XVII - for exemplary purposes only and does not form a part of the invention
[0077] Catalyst XVII was produced in the same manner as for Catalyst XV, except that a CuO
powder and the aforementioned H-type mordenite (LZM8 produced by UOP) were used in
the same proportions, and a Pt-carried Al
2O
3 powder (the amount of Pt carried: 0.04 wt.%) was further added.
Catalyst XVIII
[0078] Catalyst XVIII was produced in the same manner as for Catalyst XV, except that β-type
zeolite having a SiO
2/Al
2O
3 molar ratio of 25 (Zeolite β produced by UOP) was used instead of the H-type mordenite
of Catalyst XV.
Catalyst XIX
[0079] Catalyst XIX was produced in the same manner as for Catalyst XV, except that MFI-type
zeolite having a SiO
2/Al
2O
3 molar ratio of 30 (CBV-3020 produced by Zeolist) was used instead of the H-type mordenite
of Catalyst XV.
Catalyst XX
[0080] Catalyst XX was produced in the same manner as for Catalyst XV, except that MFI-type
zeolite having a SiO
2/Al
2O
3 molar ratio of 50 (CBV-5524 produced by Zeolist) was used instead of the H-type mordenite
of Catalyst XV.
[0081] The compositions of Catalysts I to XX are shown in Table 1 below. The proportion
of each component is expressed as wt.% to the sum of the weights of CuO and zeolite.
[0082] [Table 1]
Table 1 Catalyst compositions (Examples)
| Catalyst |
Weight of CuO |
Type (upper) and weight (lower) of zeolite |
SiO2/Al2O3 ratio (mole) of zeolite |
Type (upper) and weight (lower) of active component other than CuO and zeolite |
| I |
2.2 |
H-mordenite 97.8 |
10.7 |
- |
| II |
6.9 |
H-mordenite 93.1 |
10.7 |
- |
| III |
12.3 |
H-mordenite 87.7 |
10.7 |
- |
| IV |
2.2 |
Fe-mordenite 97.8 |
10.7 |
- |
| V |
0.2 |
Fe-mordenite |
10.7 |
MnO2 |
| 99.8 |
0.5 |
| VI |
0.5 |
Cu-mordenite |
10.7 |
MnO2 |
| 99.5 |
1.6 |
| VII |
0.8 |
Fe-mordenite |
10.7 |
MnO2 |
| 99.2 |
2.7 |
| VIII |
2.2 |
H-mordenite |
10.7 |
Pt/SiO2 |
| 97.8 |
0.01 |
| IX |
6.0 |
H-ZSM5 94.0 |
40.0 |
- |
| X |
6.3 |
H-mordenite |
10.7 |
MnO2 |
| 93.7 |
0.7 |
| XI |
1.7 |
Fe-mordenite |
10.7 |
MnO2 |
| 98.3 |
6.0 |
| XII |
11.7 |
H-mordenite |
10.7 |
Pt/TiO2 |
| 88.3 |
0.014 |
| XIII |
24.0 |
H-mordenite 76.0 |
18 |
- |
| XIV |
13.0 |
H-mordenite 87.0 |
18 |
- |
| XV |
13.0 |
H-mordenite |
18 |
Pt/TiO2 |
| 87.0 |
0.014 |
| XVI |
13.0 |
H-mordenite |
18 |
Pt/SiO2 |
| 87.0 |
0.014 |
| XVII |
13.0 |
H-mordenite |
18 |
Pd/Al2O3 |
| 87.0 |
0.014 |
| XVIII |
13.0 |
H-β zeolite |
25 |
Pt/TiO2 |
| 87.0 |
0.014 |
| XIX |
13.0 |
H-ZSM |
30 |
Pt/TiO2 |
| 87.0 |
0.014 |
| XX |
13.0 |
H-ZSM |
50 |
Pt/TiO2 |
| 87.0 |
0.014 |
*The weight of each component was expressed as a proportion
(%) to the sum of the weights of CuO and zeolite.
**MnO2 in Catalysts V to VII and XI is present as a component of hopcalite. |
<Comparative Examples>
Catalyst A
[0083] Catalyst A was produced in the same manner as for Catalyst IV, except that CuO was
all replaced by Fe-mordenite.
Catalyst B
[0084] Catalyst B was produced in the same manner as for Catalyst V, except that Fe-mordenite
was all replaced by hopcalite.
Catalyst C
[0085] Catalyst C was produced in the same manner as for Catalyst V with the use of a mixed
slurry consisting of 25.6 g of a pulverization product of a commercially available
denitration catalyst (produced by Catalyst & Chemicals Industries), 2.1 g of hopcalite,
32 g of silica sol, and 20 g of water.
Catalyst D
[0086] A slurry was prepared using 1.3 g of a MnO
2 powder, 25 g of NH
4-SCM5, 28 g of alumina sol, and 26 g of water. Using this slurry, Catalyst D was produced
in the same manner as for Catalyst I.
Catalyst E
[0087] Catalyst E was produced in the same manner as for Catalyst A, except that Fe-mordenite
was all replaced by Cu-ZSM5.
Catalyst F
[0088] Catalyst F was produced in the same manner as for Catalyst D, except that a Pt-carried
alumina catalyst was used instead of Cu-mordenite.
Catalyst G
[0089] Catalyst G was produced in the same manner as for Catalyst XV, except that H-type
mordenite having a SiO
2/Al
2O
3 molar ratio of 240 (HSZ-690HOA produced by TOSOH CORP.) was used instead of the H-type
mordenite of Catalyst XV.
Catalyst H
[0090] Catalyst H was produced in the same manner as for Catalyst XV, except that Na-type
mordenite having a SiO
2/Al
2O
3 molar ratio of 18 (HSZ-642NAA produced by TOSOH CORP.) was used instead of the H-type
mordenite of Catalyst XV.
Catalyst I
[0091] Copper nitrate (20.0 g) and 14.0 g of magnesium nitrate were dissolved in 100 g of
deionized water. An H-ZSM5 zeolite (H-MFI40 produced by UOP, SiO
2/Al
2O
3 molar ratio 40) powder (61 g) and 22.6 g of a β-type zeolite (CBV-3020 produced by
Zeolist, SiO
2/Al
2O
3 molar ratio 30) powder were charged into the solution. After thorough stirring, the
mixture was dried for 10 hours at 120° in a dryer. The resulting powder was further
pulverized in an agate mortar, and the powder obtained was calcined for 2 hours at
500°C in air to obtain a zeolite powder containing CuO and MgO. The resulting powder
(21.6 g) and 25.9 g of a silica binder were charged into 31 g of deionized water to
prepare a slurry. The slurry was wash-coated onto the same corrugated honeycomb as
used in the production of Catalyst I, and the coated honeycomb was dried for 2 hours
at 150°C. Then, the honeycomb was calcined for 1 hour at 500°C in air to obtain Catalyst
I.
[0092] The composition of the resulting catalyst carried on the honeycomb (catalyst I) per
liter was as follows:
CuO: 6.3 g; MgO: 2.1 g; zeolite 80.4 g (breakdown: H-ZSM5: 63.5 g, β: 16.9 g); CuO:zeolite
(weight ratio) = 7.3:92.7; MgO content (wt.% to the sum of CuO and zeolite): 2.4%.
[0093] The compositions of Catalysts A to I are shown in Table 2.
[0094] [Table 2]
Table 2 Catalyst compositions (Comparative Examples)
| Catalyst |
Weight of CuO |
Type (upper) and weight (lower) of zeolite |
SiO2/Al2O3 ratio (mole) of zeolite |
Type (upper) and weight (lower) of active component other than CuO and zeolite |
| A |
- |
Fe-mordenite |
10.7 |
- |
| 100 |
| B |
100 |
- |
|
MnO2 |
| |
346 |
| C |
100 |
- |
|
WOx, VOx, MnO2 |
| D |
- |
H-mordenite |
10.7 |
MnO2 |
| 100 |
5.2 |
| E |
- |
Cu-ZSM5 |
40 |
- |
| 100 |
| F |
- |
- |
|
Pt/Al2O3 |
| G |
13 |
H-mordenite |
240 |
Pt/TiO2 |
| 87 |
| H |
13 |
Na-mordenite |
18 |
Pt/TiO2 |
| 87 |
| I |
73 |
H-ZSM5+β zeolite |
about 35 |
MgO |
| 92.7 |
2.4 |
*In Catalysts A to C, the weight of each component was expressed as a proportion (%)
to the sum of the weights of CuO and zeolite.
In Catalysts D and E, only Cu-ZSM5 and Pt/Al2O3, respectively, were used as the active component.
**MnO2 in Catalysts B and C is present as a component of hopcalite. |
[Evaluation Example 1]
[0095] A gas containing dimethylformamide was passed through each of the above-mentioned
honeycomb-shaped catalysts to evaluate catalytic activity. The composition of the
gas used is as follows:
| Dimethylformamide (DMF) |
3000 ppm |
| O2 |
10 mol% |
| Water |
1 mol% |
| Nitrogen |
Remainder |
SV was set at 10,000 hr
-1, and the reaction temperatures were set at 300°C, 350°C, 400°C and 450°C.
[0096] Detailed measuring conditions are as follows: First, a reactor was packed with the
catalyst, and heated to a predetermined temperature while N
2 was being flowed. The flow rate of each component of the gas was adjusted to make
a predetermined gas composition, whereafter measurement was started. Sampling was
performed at the inlet and the outlet of the reactor. Assays of various components
were made using the following methods:
NO and NO2: Chemiluminescence
CO: Controlled-potential electrolysis
NH3, CO2 and N2O: Gas chromatography (TCD)
DMF, other products: Gas chromatography (FID)
[0098] The amounts of nitrogen-containing organic compounds formed (expressed as "other
N-containing components"), which were contained in the gas after passage through the
reactor and which were other than NH
3, NO
x and N
2O, were calculated by the following method: First, a Pt catalyst was further installed
at the outlet of the catalyst to convert remaining DMF, generated NH
3, and "other N-containing components", which were contained in the gas after passage
through the catalyst of the present invention, into N
2, NO
x and N
2O. The gas after passage through this Pt catalyst was analyzed by the above-described
methods to determine the NO
x yield and the N
2O yield. These yields will be described hereinafter as NO
x yield (Pt) and N
2O yield (Pt). Not only NO
x and N
2O formed by the catalyst of the present invention, but also NO
x and N
2O derived from DMF, NH
3 and "other N-containing components" by the Pt catalyst contribute to NO
x yield (Pt) and N
2O yield (Pt).

[0099] It was assumed that 80% of nitrogen of DMF, NH
3 and "other N-containing components" was converted to NO
x and N
2O by the Pt catalyst, and 20% of the nitrogen was converted to N
2.

[0100] The yield of other N-containing components was calculated from the following equation
based on the above two equations:

[0101] The N
2 yield was determined by the following equation:

[0102] The results of evaluation are shown in Tables 3 and 4 below. In connection with Catalysts
I, II, VII and VIII of the present invention, and Catalysts A and F as Comparative
Examples, the N
2 yields at the reaction temperatures of 300 to 450°C are shown in Fig. 1.
[0103]
[Table 3] Table 3 Yields of nitrogen-based products in catalytic reaction of DMF-containing
gas (reaction temperature 350°C)
| Catalyst |
Yield (%) |
| N2 |
NOx |
N2O |
NH3 |
Other N-containing components |
| I |
98.3 |
0.7 |
0.7 |
0.3 |
0.0 |
| II |
96.8 |
0.5 |
2.7 |
0.0 |
0.0 |
| III |
94.9 |
0.7 |
4.4 |
0.0 |
0.0 |
| IV |
99.2 |
0.0 |
0.0 |
0.3 |
0.5 |
| V |
84.9 |
1.0 |
4.4 |
9.3 |
0.4 |
| VI |
89.0 |
0.2 |
10.8 |
0.0 |
0.0 |
| VII |
94.4 |
0.0 |
5.6 |
0.0 |
0.0 |
| VIII |
79.6 |
11.6 |
8.7 |
0.1 |
0.0 |
| IX |
97.7 |
0.6 |
1.6 |
0.1 |
0.0 |
| X |
93.0 |
1.8 |
5.2 |
0.0 |
0.0 |
| XI |
91.4 |
2.2 |
6.4 |
0.0 |
0.0 |
| XII |
94.9 |
0.1 |
5.0 |
0.0 |
0.0 |
| XIII |
94.9 |
0.7 |
4.4 |
0.0 |
0.0 |
| XIV |
95.3 |
0.2 |
4.5 |
0.0 |
0.0 |
| XV |
94.7 |
0.2 |
5.1 |
0.0 |
0.0 |
| XVI |
91.8 |
0.7 |
7.5 |
0.0 |
0.0 |
| XVII |
81.5 |
15.4 |
3.1 |
0.0 |
0.0 |
| XVIII |
92.4 |
0.1 |
7.1 |
0.0 |
0.4 |
| XIX |
95.4 |
0.5 |
4.1 |
0.0 |
0.0 |
| XX |
94.2 |
1.0 |
4.8 |
0.0 |
0.0 |
| A |
31.7 |
0.4 |
0.0 |
32.8 |
35.1 |
| B |
58.3 |
15.1 |
26.6 |
0.0 |
0.0 |
| C |
79.4 |
3.5 |
9.8 |
7.3 |
0.0 |
| D |
78.1 |
10.4 |
11.5 |
0.0 |
0.0 |
| E |
49.7 |
2.4 |
1.3 |
10.6 |
34.8 |
| F |
28.0 |
39.0 |
33.0 |
0.0 |
0.0 |
| G |
69.1 |
22.8 |
8.1 |
0.0 |
0.0 |
| H |
63.1 |
29.0 |
7.9 |
0.0 |
0.0 |
| I |
74.3 |
3.9 |
3.2 |
13.5 |
4.1 |
Note 1: The DMF decomposition rate of Catalysts A to H was 100%.
Note 2: The DMF decomposition rate of Catalyst I was 99%. |
[Table 4]
Table 4 Yields of nitrogen-based products in catalytic reaction of DMF-containing
gas (reaction temperature 400°C)
| Catalyst |
Yield (%) |
| N2 |
NOx |
N2O |
NH3 |
Other N-containing components |
| I |
98.5 |
0.4 |
1.1 |
0.0 |
0.0 |
| II |
93.7 |
1..3 |
5.0 |
0.0 |
0.0 |
| III |
88.6 |
3.9 |
7.5 |
0.0 |
0.0 |
| IV |
100.0 |
0.0 |
0.0 |
0.0 |
0.0 |
| V |
99.8 |
0.1 |
0.0 |
0.1 |
0.0 |
| VI |
90.4 |
0.4 |
9.2 |
0.0 |
0.0 |
| VII |
96.7 |
1.3 |
2.0 |
0.0 |
0.0 |
| VIII |
88.7 |
0.4 |
1.9 |
0.0 |
0.0 |
| IX |
96.0 |
0.8 |
3.2 |
0.0 |
0.0 |
| X |
93.3 |
0.3 |
6.4 |
0.0 |
0.0 |
| XI |
93.7 |
3.3 |
3.0 |
0.0 |
0.0 |
| XII |
90.9 |
1.6 |
7.5 |
0.0 |
0.0 |
| XIII |
88.6 |
3.9 |
7.5 |
0.0 |
0.0 |
| XIV |
90.5 |
2.0 |
7.5 |
0.0 |
0.0 |
| XV |
89.6 |
2.6 |
7.8 |
0.0 |
0.0 |
| XVI |
88.9 |
3.0 |
8.1 |
0.0 |
0.0 |
| XVII |
78.4 |
19.4 |
2.2 |
0.0 |
0.0 |
| XVIII |
88.8 |
1.2 |
10.0 |
0.0 |
0.0 |
| XIX |
94.7 |
1.4 |
3.9 |
0.0 |
0.0 |
| XX |
91.0 |
4.2 |
4.8 |
0.0 |
0.0 |
| A |
63.1 |
0.2 |
0.0 |
36.7 |
0.0 |
| B |
44.4 |
26.5 |
29.1 |
0.0 |
0.0 |
| C |
72.3 |
10.8 |
12.7 |
0.3 |
3.9 |
| D |
66.1 |
22.9 |
11.0 |
0.0 |
0.0 |
| E |
99.2 |
0.7 |
0.0 |
0.1 |
0.0 |
| F |
26.0 |
55.0 |
19.0 |
0.0 |
0.0 |
| G |
62.2 |
29.5 |
8.3 |
0.0 |
0.0 |
| H |
58.8 |
33.7 |
7.5 |
0.0 |
0.0 |
| I |
95.5 |
1.3 |
2.7 |
0.0 |
0.5 |
| Note 1: The DMF decomposition rate of all catalysts was 100%. |
[0104] As shown in Table 3, Table 4 and Fig. 1, the catalysts containing copper oxide and
zeolite are demonstrated to be catalysts which decompose DMF at a rate of nearly 100%,
suppress the formation of NH
3, NO
x, N
2O, other N-containing components, and CO, and achieve a high rate of conversion into
N
2, at 350°C to 450°C. With Catalysts I to IV, VII, IX to XI, for example, the rates
of conversion into N
2 are 90% or higher.
[0105] In comparison, the catalysts free from copper oxide and containing zeolite along
(Catalysts A and D) form large amounts of NH
3 or N-containing components at 350°C, showing extremely low N
2 selectivity. The copper oxide-based catalysts (B and C) and the previous metal-based
catalyst (Catalyst F), both free from zeolite, have high selection rates of NO
x and/or N
2O, and show low N
2 selectivity. The catalyst I as the Comparative example, containing MgO, forms a large
amount of NH
3 at 350°C, showing a low N
2 yield.
[0106] Thus, the catalysts of the present invention can be said to show excellent performance
in treating a nitrogen-based exhaust gas.
[0107] Next, a comparison was made of the evaluation results on the catalyst of the present
invention comprising a mixture of a copper oxide and zeolite (Catalyst IX), and the
catalyst as the comparative example which was ion-exchanged with Cu (Catalyst E) (Table
5 and Fig. 2).
[0108] [Table 5]
Table 5 Results of evaluation of catalytic performance for DMF-containing gas: A comparison
of CuO+H-zeolite (Catalyst IX) and Cu-substituted zeolite (Catalyst E)
| Catalyst |
Reaction temp. |
DMF decomposition rate |
Yield (%) |
| °C |
(%) |
N2 |
NH3 |
NOx |
N2O |
Other N-containing component |
CO |
| IX |
300 |
100 |
76.2 |
14.6 |
0.5 |
0.2 |
8.5 |
6.8 |
| 350 |
100 |
97.7 |
0.1 |
0.6 |
1.6 |
0 |
2.5 |
| 400 |
100 |
96.0 |
0.0 |
0.8 |
3.2 |
0 |
0 |
| 450 |
100 |
95.8 |
0.0 |
0.7 |
3.5 |
0 |
0 |
| E |
300 |
79 |
37.2 |
8.2 |
1.4 |
0 |
39.9 |
14.4 |
| 350 |
98.8 |
31.7 |
10.6 |
0.4 |
1.3 |
34.8 |
28.1 |
| 400 |
100 |
63.1 |
0.1 |
0.2 |
0 |
0 |
0 |
| 450 |
100 |
99.2 |
0.0 |
0.2 |
0 |
0 |
0 |
[0109] Firstly, the DMF decomposition rate, at 300°C, of the catalyst comprising a mixture
of the copper oxide and zeolite (Catalyst IX) is 100%, while that of Cu-ZSM5 which
is zeolite ion-exchanged with Cu (Catalyst E) is 79%, showing that Catalyst IX has
higher activity.
[0110] Furthermore, the N
2 selection rates, at 300 to 350°C, of Catalyst IX are 76 to 98%, those of Catalyst
E as the comparative example are 32 to 47%, showing that Catalyst IX is also better
in selectivity. In connection with the selection rates of CO ascribed to the hydrocarbon
component of DMF, Catalyst IX shows the rates of about 2 to 7% at 300 to 350°C, while
Catalyst E as the comparative example gave the rates of 18 to 28%. These results show
that the use of the catalyst of the present invention can suppress the formation of
CO.
[0111] As is clear from the above findings, the catalyst of the present invention forms
extremely small amounts of NO
x, N
2O and CO, and can achieve conversion into N
2 at a high selection rate, even under the condition that the decomposition rate of
the organic nitrogen compound is nearly 100%.
[Evaluation Example 2]
[0112] A gas containing ammonia was passed through the above-mentioned catalysts to evaluate
catalytic activity. The composition of the gas used is as follows:
| Ammonia |
5000 ppm |
| O2 |
10 mol% |
| Water |
2 mol% |
| Nitrogen |
Remainder |
The conditions for measurement were the same as those in Evaluation Example 1.
[0113] The evaluation results on Catalysts II, XI and XII are shown in Table 6 below and
Fig. 3.
[0114] [Table 6]
Table 6 Results of evaluation of catalytic performance for NH
3-containing gas
| Catalyst |
Temperature °C |
Decomposition rate of NH3 (%) |
Yield (%) |
| N2 |
NOx |
N2O |
| II |
350 |
99.7 |
98.3 |
0.0 |
1.4 |
| 400 |
99.9 |
99.9 |
0.0 |
0.0 |
| XI |
350 |
99.3 |
82.0 |
0.0 |
17.3 |
| 400 |
99.9 |
93.6 |
0.0 |
6.3 |
| XII |
350 |
100 |
98.6 |
0.1 |
1.3 |
| 400 |
100 |
99.2 |
0.0 |
0.8 |
[0115] As shown in Table 6 and Table 3, the catalysts of the present invention clearly convert
ammonia into N
2 at extremely high selection rates.
[0116] Table 7 shows a comparison of the DMF decomposition properties of the catalysts having
compositions in which the type of zeolite is changed.
[Table 7]
Table 7 Results of evaluation of catalytic performance for DMF-containing gas
| Catalyst |
Type of zeolite SiO2/Al2O3 ratio |
Reaction temp. |
DMF decomp. rate |
Yield (%) |
| °C |
(%) |
N2 |
NH3 |
NOx |
N2O |
Other N-containing component |
CO |
| XII |
|
300 |
100 |
97.1 |
1.5 |
0 |
1.4 |
0 |
0 |
| H-mordenite |
350 |
100 |
94.9 |
0 |
0.1 |
5 |
0 |
0 |
| 10.7 |
400 |
100 |
90.9 |
0 |
1.6 |
7.5 |
0 |
0 |
| |
450 |
100 |
84.2 |
0 |
6.1 |
9.7 |
0 |
0 |
| XV |
|
300 |
100 |
97.5 |
0.1 |
0 |
1.8 |
0.6 |
0.6 |
| H-mordenite |
350 |
100 |
94.7 |
0 |
0.2 |
5.1 |
0.4 |
0.1 |
| 18 |
400 |
100 |
89.6 |
0 |
2.6 |
7.8 |
0 |
0 |
| |
450 |
100 |
84.2 |
0 |
5.8 |
10 |
0 |
0 |
| XVIII |
|
300 |
100 |
84.87 |
0.5 |
0.1 |
4.1 |
0.5 |
0.7 |
| β |
350 |
100 |
92.7 |
0 |
0.1 |
7.1 |
0.1 |
0 |
| 25 |
400 |
100 |
88.8 |
0 |
1.2 |
10 |
0 |
0 |
| |
450 |
100 |
83 |
0 |
7.8 |
9.2 |
0 |
0 |
| XIX |
|
300 |
100 |
95.9 |
0 |
0.1 |
4 |
0 |
0.1 |
| H-ZSM |
350 |
100 |
95.4 |
0 |
0.5 |
4.1 |
0 |
0 |
| 30 |
400 |
100 |
94.7 |
0 |
1.4 |
3.9 |
0 |
0 |
| |
450 |
100 |
93.5 |
0 |
3.4 |
3.1 |
0 |
0 |
| XX |
|
300 |
100 |
94.4 |
0 |
0.8 |
4.8 |
0 |
0.1 |
| H-ZSM |
350 |
100 |
94.2 |
0 |
1 |
4.8 |
0 |
0 |
| 50 |
400 |
100 |
91 |
0 |
4.2 |
4.8 |
0 |
0 |
| |
450 |
100 |
82.6 |
0 |
12.6 |
4.8 |
0 |
0 |
| G |
|
300 |
100 |
76.9 |
0 |
16.1 |
7 |
0 |
6.8 |
| H-mordenite |
350 |
100 |
69.1 |
0 |
22.8 |
8.1 |
0 |
2.6 |
| 240 |
400 |
100 |
62.2 |
0 |
29.5 |
8.3 |
0 |
1 |
| |
450 |
100 |
53.2 |
0 |
39.3 |
7.5 |
0 |
0.3 |
| H |
|
300 |
100 |
71.8 |
0 |
21 |
7.2 |
0 |
1.6 |
| Na-mordenite |
350 |
100 |
63.1 |
0 |
29 |
7.9 |
0 |
0.3 |
| 18 |
400 |
100 |
58.8 |
0 |
33.7 |
7.5 |
0 |
0.1 |
| |
450 |
100 |
52.6 |
0 |
41.3 |
6.1 |
0 |
0.1 |
[0117] Catalyst XII using H-mordenite (SiO
2/Al
2O
3 molar ratio 10.7) decomposes DMF at a rate of 100% at 300 to 450°C, converting it
into N
2 at a rate of 84.2 to 97.1%. On the other hand, Catalyst H using Na-mordenite (SiO
2/Al
2O
3 molar ratio 10.7) decomposes DMF at a rate of 100%, but its rate of conversion into
N
2 is 52.6 to 71.8%, increasing the yields of NO
x and N
2O.
[0118] Catalyst G using H-mordenite having a SiO
2/Al
2O
3 molar ratio of 240 also gives a low N
2 conversion rate, as does Catalyst H.
[0119] By contrast, Catalyst XVIII using β-type zeolite, and Catalyst XIX and Catalyst XX,
both using H-ZSM, attain high N
2 conversion rates. These catalysts are shown to decompose an organic nitrogen compound
at a rate of 100%, involve little formation of by-products such as NH
3, NO
x, N
2O and CO, and achieve conversion into N
2 at a high rate.
[Evaluation Example 3] Accelerated durability test
[0120] Catalyst XIV and Catalyst XV were subjected to the following evaluation:
Composition of a gas passed:
| Dimethylformamide (DMF): |
3000 ppm |
| O2: |
10 mol% |
| Water: |
1 mol% |
| SO2 : |
2 ppm |
| Nitrogen: |
Remainder |
[0121] A gas of the above composition was passed through the catalyst at SV of 20,000 hr
-1 and a temperature of 350°C and, in this state, an operation was performed for 500
hours. Then, the catalyst was subjected to a DMF decomposition test under the conditions
of Evaluation Example 1. The results of the activity test of the catalyst after 500
hours were as follows:
Notes: Reaction temperature: 300°C (upper), 350°C (lower)
| |
DMF decomposition rate (%) |
N2 yield (%) |
CO yield (%) |
| Catalyst XIV: |
49.8 |
32.9 |
2.7 |
| |
100 |
90.7 |
14.6 |
| Catalyst XV: |
100 |
86.6 |
0.6 |
| |
100 |
90.5 |
2.7 |
[0122] It is clear that Catalyst XV containing Pt, even in the presence of SO
2, minimally decreases in activity, maintains a high decomposition rate of the organic
nitrogen compound, and minimally declines in the N
2 conversion rate. Because of the presence of Pt, this catalyst is effective, particularly,
in increasing the N
2 yield and decreasing the CO yield at a relatively low temperature of 300°C.